How does ISAT331 fit in the curriculum? Automation in Manufacturing How does ISAT331 fit in the curriculum?

ISAT 211 & 330 211,330 211, 330 211, 330 211, 330 Factory Operations

331 331 331 331 ISAT 331

References Groover, M.P, Automation, Production Systems, and Computer Integrated Manufacturing, Prentice-Hall 2001 Bedworth, D.D.,Henderson, M.R., and Wolfe P.M., Computer-Integrated Design and Manufacturing, McGraw-Hill, 1991. Chang,T., Wysk,R..A, Wang, H. Computer Aided Manufacturing, Prentice Hall, 2nd Ed, 1991

Module 1 Introduction 1/10/05 Production Systems Facilities Automation in Production Systems Manual Labor in Production Systems Automation Principles and Strategies CAD, CAM and CIM

CIM Terminologies Production System ISAT330 ISAT331 Manufacturing Support Activities ISAT331 Computerization Manufacturing System CIM Automation Terminologies

Computers in Manufacturing Automate physical system and information system in manufacturing Automation is more related to automating the factory operations Computerization is more related to automating information cycle CIM is more related to automating of both factory operations and information cycle

Product Variety vs Production Quantity Changeover (set up)Time Hard Soft Job Shop MH automated Production Quantity Product Variety 100 10,000 1 M Mid Variety Mid Production (Most Difficult) Mass Production Low High

Fig 1.3

Types of Production Plant (facilities) and Layout Fixed Position (Large) Process Hard Soft Production Quantity Product Variety 100 10,000 1 M Job Shop Process (Batch) Cellular (GT families) FMS (GT families- automated MH) Mid Variety Mid Production (Apply GT) Flexibility Product (Flow line) Process (Quantity) Efficiency Mass Production Low High

Characteristics of Production Plants Job Shop has processes that cope with low volume and high number of products - Uses Process or Fixed position layout - Make to order. - Production Rate = Demand Rate Batch, cellular, and FMS Production has processes that cope with medium volume and medium variety in products Cellular deals with harder variety products than FMS FMS is highly automated (MH) when compared to cellular - Repeated set up-a major disadvantage. - Production rate > Demand rate. - Make to Stock.

Characteristics of Production Plants Mass Production has processes that cope with high volume and limited number of products - Process or cellular layout is used for quantity production (single station ‘equipment’) - Product layout ’Flow Line’ when multiple stations are required (single- or mixed model lines) - Demand Rate ~ Production Rate

Automation of Production Plant Definition of Automation Why to Automate? Arguments for Automation Arguments against Automation Examples Types of Automated Manufacturing Systems Categorized based on sequence of operations Justified based on production volume and variety of products Fixed Automation Programmable Automation Flexible Automation

Manual vs Automation Hard Soft Production Quantity Product Variety 100 10,000 1 M Low High

Fig 1.1 Automation/Production Volume/Product Variety Programmable Automation Hard Soft Job Shop Production Quantity Product Variety 100 10,000 1 M Flexible Automation Change Over (Set-up) Time Manual Automation Mid Variety Mid Production (Most Difficult) Fixed Automation Mass Production Low High

Programmable Automation MOST FLEXIBLE Sequence of operations can be changed (variety of products that are made by similar processes) High investment (general purpose equipment) Low – Medium production rate (relatively longer time lost for changeovers of programming and set-up) Automation of operations (processes or workstations) is emphasized (not MH)

Fixed Automation MOST EFFICIENT Sequence of operation is fixed (fixed configurations) Many simple ( reliability) operations (complex system) Initial investment is high (custom-engineered equipment) Production rates are high (mass production-Examples) Automated Operations (processes or workstations) and Material handling

Flexible Automation Extension of Programmable Automation with Lower time lost on changeovers (continuous production of a group of parts – GT family- that accommodate part variations within the family) Mid volume/variety range Higher investment (custom-engineered devices (e.g fixtures and Jigs) for changeover)

Automation Strategies & Migration Automation is not the answer (Robotics application?) Main principle Understand (charting?), Simplify, and Automate Strategies? Automation Migration Strategy

Fig 1.9

Back to our Conceptual Model Manufacturing Support Activities Manufacturing System Back to our Conceptual Model

Factory Operations (Fig 2.2) Processing ‘advance to completion’ (Basic, Secondary, Property Enhancement, Finishing) Assembly Material handling&Storage Inspection (specifications)and Testing (function) Control on shop floor (process control, quality control)

SAP system?

Manufacturing Support Activities (Fig 2.4) Business functions (type of orders?) Product Design (source of specifications?) Manufacturing Planning (process planning and route sheet?) Manufacturing Control (management) ‘implement plans’(type of controls?), performance of processes “ # rejects, machine rate, etc”, performance of plant “operating cost, meeting schedule”, etc)

Manual Labor in Production System Factory Operations Supporting Activities

Fig 24.7 Scope of CAD, CAM and CIM

Fig 24.8

Definitions CAD is any design activity that involves the effective use of computer technology to create,modify, or document an engineering design (part or system) CAM is the effective use of computer technology in the planning, management, and control of the manufacturing function CAD/CAM integration of the design and manufacturing activities. That is to automate the transition from design to manufacturing (e.g NC and process plan and Rapid Prototyping)

Home Work#1 Due Wednesday 1/18/2006 Explain and contrast the characteristics of the basic production systems Explain and contrast the characteristics of the basic automated production systems Discuss TWO situations in which humans are preferred over automation in Factory Operations (blue collar tasks) Discuss TWO situations in which humans are preferred over automation in Manufacturing Support Systems (white collar tasks) Explain THREE strategies for automating production systems

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